Constructional material



Patented June 11, 1940 UNITED STATES PATENT OFFICE CONSTRUCTIONALMATERIAL poration of Ohio t No Drawing. Original application December 3,

1926, Serial No. 152,519.

Divided and this application August 23, 1929, Serial No. 388,044

6 Claims.

My present invention relates to a novel and improved constructionalmaterial composed of roofing scrap, and particularly pertains to suchcomposition materials as slabs, blocks, or planks which are preformedinto rail fillers, expansion joint;

paving blocks and the like.

This application is a division of Serial No. 152,519, filed December 3,1926, which relates to a process of manufacture.

In the production of composition roofing material, especially in theproduction of individual composition shingles or composition shinglestrips, the cutting operation necessary to make up the shingle designresults in considerable waste, commonly termed roofing scrap. Verylittle, if any, use is made of this roofing scrap so far as concerns theroofing manufacturer. Consequently it can be purchased at a nominalcost. The roofing material from which this scrap 1'81 sults is feltsaturated with an abundance of asphalt or other such bituminoussubstance, and I have discovered that by collecting this scrap andtreating the same as will be hereinafter explained, I can develop anunusually acceptable product. The form of the same is immaterial in sofar as concerns the present invention, although I am confined to makingthe product as a preformed piece of goods, that is to say, it is not tobe confused with a liquid substance.

This so-called roofing scrap may be collected from the roofingmanufacturers in irregular pieces or cut-out tabs and in differentthicknesses, ranging from 1 to 4 ply, depending upon the thickness ofthe material from which the scrap is left. More often the scrap would beabout /3 of an inch in thickness. Frequently the scrap will be surfacedwith subdivided mineral material, such as mica, slate particles, rockparticles, or even small pebbles as a result of cutting the tabs fromsheet material which has been surfaced with such subdivided mineralsubstance.

Since both the plain and the surfaced scrap may be obtained I am enabledto regulate the mineral content of the product which I develop by mixingmeasured quantities of mineral surfaced scrap with measured quantitiesof the unsurfaced scrap. On the other hand I may eliminate such amineral content in the product by using the unsurfaced scrap in themixture.

In treating the scrap to develop the products as explained, I employ asa first step in the process or method some means that will subject thescrap to a sufliciently high temperature to melt the asphalt orbituminous material with which the felt is saturated. Since an essentialstep in the process involves an agitation or thorough mixing I havefound that a heavy duty steamjacketed mechanical mixing apparatus issuitable for this purpose. The materials introduced into such a mixerare thoroughly agitated at a tem- 5 perature suflicient to melt thebituminous substance. Care should be taken that the mixing operationcontinues for a sufflcient length of time to completely melt thebituminous substance as well as thoroughly mix the released felt fibers,so that a uniform mixture results. Successive quantities of the scrapmay be introduced into the apparatus rather than filling the apparatusto capacity at one time. This will insure a better mixture.

After the mixing step the mixture is removed from the apparatus, andwithout undue loss of time, that is to say, while it is in a warmplastic fiowable condition I extrude the same into the productshereinbefore mentioned. This second step may be carried out in variousways. Fon the most part I would prefer to use an extruding apparatus.The material while, as stated, being; in a warm, plastic, fiowablecondition, I am en-1 abled to extrude it into various preformedproducts, such as, blocks, slabs, boards, bricks, cylinders, tubes, orany possible design or shape that an extruding apparatus is equipped toaccommo-x date. In lieu of the extruding apparatus it is possible to usea sheet forming apparatus which will reduce the material into sheets,and the sheets may then be cut in any desired shape, for instance, asstrips, boards, planks, or the like. The sheet forming apparatus can beregulated to predetermine the thickness of the sheets, with the resultthat in using the sheet forming apparatus instead of the extrudingapparatus I am not confined to making products with a reduced thickness.

After being extruded or otherwise formed into the ultimate shape of theproducts desired I would ordinarily compress the same with a hydraulicpressing machine to increase the density of the product. The amount ofpressure used would determine the inherent quality of the ultimateproduct. For instance, in making up a paving block or a brick, or anyother product that would be subjected to traflic or other wearingconditions, or where it was to be expected that the product wouldsupport a weight, as in the case of a foundation, the density of theproduct should be at its maximum, whereas in the case of uses where itwould not be subjected to wear and tear, as in the case of a lining forinsulation purposes, it need not be compressed to its maximum. Fur- 55thermore, regulating the compression or the density of the product willadapt the material to certain uses to its greatest efliciency, as in thecase of uses which would require inherent compressibility in the productit would not be desirable to use too much pressure. For this reason thecompression towhich the products are subjected is a more or lesscontrolling factor so far as concerns the product.

From the above it will be seen that by simply taking this roofing scrapas it is left after cuting the sheets into shingles or shingle strips,and without the addition of any other material I can developconstruction material which will have the inherent qualities of water ormoisture proofing, soundproofing, and a material that will withstandwear and tear of trafiic in streets, floors, bridge flooring, or thatmay be used for other purposes. It may be manufactured economically,conveniently, and is well adapted to serve a variety of purposes,depending upon the way that it is made.

In the sub-joined claims, where the term roofing scrap" is used it isintended that the same should be interpreted as covering roofingmaterial of the class herein referred to, that is to say, sheets of feltsaturated with bituminous material as the same are known to thecomposition roofing art.

I claim:

1. A preformed construction block-like strip containing a plasticwaterproof binder, shredded fibrous waste materials and mineralparticles.

2. A preformed construction block-like strip containing a plasticwaterproof binder and shredded roofing waste comprised of felt saturatedand coated with asphalt and surfaced with granular material.

3. A preformed construction block-like strip containing a plasticwaterproof binder and shredded roofing waste comprised of felt saturatedand coated with asphalt.

4. A preformed construction block-like strip containing a plasticwaterproof binder and shredded waste bituminized fabrics.

5. A preformed construction block-like strip containing a plasticwaterproof binder and shredded asphalt roofing waste.

6. A preformed construction block-like strip containing a plasticwaterproof binder and shredded fibrous waste materials.

ALBERT C. FISCHER.

